U.S. patent application number 13/775602 was filed with the patent office on 2013-08-29 for switch assembly with sequentially actuated power and neutral switching.
This patent application is currently assigned to Reliance Controls Corporation. The applicant listed for this patent is Reliance Controls Corporation. Invention is credited to Neil A. Czarnecki.
Application Number | 20130220781 13/775602 |
Document ID | / |
Family ID | 49001647 |
Filed Date | 2013-08-29 |
United States Patent
Application |
20130220781 |
Kind Code |
A1 |
Czarnecki; Neil A. |
August 29, 2013 |
Switch Assembly With Sequentially Actuated Power and Neutral
Switching
Abstract
A switch assembly and method of switching a load between a first
power source and a second power source that maintains a desired
sequencing of the making and breaking of both the neutral and power
connections in response to a single user input. The switch assembly
includes an actuator that is movable between a first position and a
second position and a first movable element and a second movable
element that are operably coupled to one another and the actuator.
A positive switch contact arrangement is coupled with the first
movable element and a neutral switch contact arrangement is coupled
with the second movable element. The positive switch contact
arrangement and the neutral switch contact arrangement comprise
geometrically different constructions so that moving the actuator
between the first position and the second position avoids an open
neutral condition.
Inventors: |
Czarnecki; Neil A.; (Mt.
Pleasant, WI) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Reliance Controls Corporation; |
|
|
US |
|
|
Assignee: |
Reliance Controls
Corporation
Racine
WI
|
Family ID: |
49001647 |
Appl. No.: |
13/775602 |
Filed: |
February 25, 2013 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61604842 |
Feb 29, 2012 |
|
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|
Current U.S.
Class: |
200/50.37 ;
29/622 |
Current CPC
Class: |
H01H 11/00 20130101;
H01H 1/2016 20130101; H01H 23/168 20130101; H01H 9/24 20130101;
H01H 23/24 20130101; Y10T 29/49105 20150115; H01H 2300/018
20130101; H01H 23/205 20130101 |
Class at
Publication: |
200/50.37 ;
29/622 |
International
Class: |
H01H 9/24 20060101
H01H009/24; H01H 11/00 20060101 H01H011/00 |
Claims
1. A switch assembly comprising: an actuator movable between a
first position and a second position; a first movable element and a
second movable element operably coupled to one another and the
actuator; a positive switch contact arrangement coupled with the
first movable element; a neutral switch contact arrangement coupled
with the second movable element; and wherein the positive switch
contact arrangement and the neutral switch contact arrangement
comprise geometrically different constructions so that when moving
the actuator between a first position and a second position, the
switch assembly avoids an open neutral condition.
2. The switch assembly of claim 1, wherein the positive switch
contact arrangement comprises a conductive support including a
first portion and a second portion, wherein the first portion and
the second portion respectively carry a contact switch element that
are selectively engageable with a corresponding contact element for
selectively coupling a respective contact switch element to one of
a utility power source and a secondary power source.
3. The switch assembly of claim 1, wherein the neutral switch
contact arrangement comprises a conductive support including a
first portion and a second portion, wherein the first portion and
the second portion respectively carry a contact switch element that
are selectively engageable with a corresponding contact element for
selectively coupling a respective contact switch element to one of
a utility power source and a secondary power source.
4. The switch assembly of claim 1, wherein the positive switch
contact arrangement and the neutral switch contact arrangement
comprise respective conductive supports including a first portion
and a second portion, wherein the respective first portions and the
second portions carry a contact switch element that is selectively
engageable with a corresponding respective contact element for
selectively coupling a respective contact switch element of each of
the positive switch contact arrangement and the neutral switch
contact arrangement with a first power source and a second power
source, wherein the first portion and the second portion of the
positive switch contact arrangement and the neutral switch contact
each define an obtuse angle therebetween, and wherein the obtuse
angle defined by the neutral switch contact arrangement is greater
than the obtuse angle of the positive switch contact
arrangement.
5. The switch assembly of claim 1, wherein the actuator is operably
coupled with the first movable element and the second movable
element so that movement of the actuator between the first position
and the second position moves the first movable element and the
second movable element in a predetermined sequence.
6. The switch assembly of claim 5 further comprising a housing that
pivotably supports the actuator relative to the positive switch
contact arrangement and the neutral switch contact arrangement.
7. The switch assembly of claim 6, wherein the housing further
comprises at least one tang shaped to define a position of a pivot
relative to the positive switch contact arrangement and the neutral
switch contact arrangement.
8. A switch assembly comprising: a first neutral contact and a
second neutral contact; a first power contact and a second power
contact; a neutral conductor that is movable between a first
position wherein the neutral conductor is electrically connected to
the first neutral contact and is electrically isolated from the
second neutral contact and a second position wherein the neutral
conductor is electrically connected to the second neutral contact
and is electrically isolated from the first neutral contact; a
power conductor that is movable between a first position wherein
the power conductor is electrically connected to the first power
contact and is electrically isolated from the second power contact
and a second position wherein the power conductor is electrically
connected to the second power contact and is electrically isolated
from the second power contact; and a single actuator that
effectuates sequential movement of the neutral conductor and the
power conductor between their respective first and second positions
such that the neutral conductor remains in the neutral conductor
first position after the power conductor moves from the power
conductor first position and arrives at the neutral conductor
second position before the power conductor arrives at the power
conductor second position.
9. The switch assembly of claim 8 further comprising a third
neutral contact that is electrically connected to the neutral
conductor when the neutral conductor is at or between the first and
second positions of the neutral conductor.
10. The switch assembly of claim 9 further comprising a third power
contact that is electrically connected to the power conductor when
the neutral conductor is at or between the first and second
positions of the power conductor.
11. The switch assembly of claim 10 further comprising a control
arrangement that is attached to the single actuator, the control
arrangement including a first portion that is associated with
movement of the neutral conductor and a second portion that is
associated with movement of the power conductor between their
respective first and second positions.
12. The switch assembly of claim 11 wherein the first portion and
the second portion of the control arrangement each include sections
that are oriented at obtuse angles relative to one another and the
obtuse angle associated with the first portion of the control
arrangement is greater than the obtuse angle associated with the
second portion of the control arrangement.
13. The switch assembly of claim 10 further comprising a control
arrangement that is attached to the single actuator and which
defines an apex that is movable between alternate lateral sides of
the third neutral contact and the third power contact.
14. The switch assembly of claim 13 wherein neutral conductor is
electrically isolated from both the first neutral contact and the
second neutral contact and the power conductor is electrically
isolated from both the first power contact and the second power
contact when the apex is aligned with the first neutral contact and
the third power contact.
15. A method of switching a load between a first power source and a
second power source, the method comprising: providing an actuator
having a first portion and a second portion; shaping a first
portion of the actuator for cooperation with a power conductor that
is selectively electrically connectable to one of a first power
contact and a second power contact and is not electrically
isolatable from a third power contact; shaping a second portion of
the actuator for cooperation with a neutral conductor that is
selectively electrically connectable to one of a first neutral
contact and a second neutral contact and is not electrically
isolatable from a third neutral contact; and positionally
associating the actuator relative to the power conductor and the
neutral conductor so that movement of the actuator from a first
position to a second position: 1) electrically isolates the neutral
conductor from each of the first neutral contact and the second
neutral contact before the power conductor is electrically isolated
from a respective one of the first power contact and the second
power contact; and 2) electrically connects the neutral conductor
to one of the first neutral contact and the second neutral contact
before the power conductor is electrically connected to the other
respective one of the first power contact and the second power
contact.
16. The method of claim 15 further comprising pivotably supporting
the actuator in a housing so that a user end extends in a direction
opposite the first and second portions relative to a pivot
axis.
17. The method of claim 15 wherein shaping a first portion of the
actuator and shaping the second portion of the actuator further
comprises forming the first portion to occupy a smaller footprint
than the second portion relative to a direction that is transverse
to a plane of movement of the actuator.
18. The method of claim 17 further comprising forming an apex on
the first portion and an apex on the second portion that are each
aligned with a respective one of the third power contact and the
third neutral contact when the actuator is between the first and
second positions.
19. The method of claim 17 further comprising electrically
isolating the neutral conductor from the first neutral contact and
the second neutral contact when the second portion of the actuator
overlaps the third neutral contact and electrically isolating the
power conductor from the first power contact and the second power
contact when the first portion of the actuator overlaps the third
power contact.
20. The method of claim 15 further comprising bending the power
conductor and the neutral conductor at different angles relative to
one another and at different angles relative to the respective
first portion and second portion of the actuator.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional Patent
Application Ser. No. 61/604,842, filed on Feb. 29, 2012, titled
"Sequentially Actuated Power And Neutral Switch" and the entire
contents of which are expressly incorporated herein.
BACKGROUND AND SUMMARY OF THE INVENTION
[0002] The present invention relates to a switch assembly for
switching between power sources, such as between utility power and
an auxiliary power source such as, for example, a backup power
source such as a gasoline or other combustible fuel powered
generator. The switch is configured to prevent the occurrence of
open-neutral configurations that present the potential for
high-voltages, e.g., 240 VAC, to be erroneously applied to 120 VAC
equipment or appliances, which may cause damage to the equipment or
appliances.
[0003] Electrical panels, breaker boxes, or load centers frequently
include a main contactor, switch, or breaker, which electrically
isolates a series of load breakers from a utility power input.
Certain types of load centers, such as transfer switches or
transfer panels, are configured to receive another input power
source, such as from a generator, to provide electrical power to
selected individual loads in the event of a utility power failure.
During interruption of utility power, the generator supplies power
to the load center, which the load center distributes to the
selected or designated circuits of the building. Before activating
the generator power supply, the main switch must be disconnected or
turned "OFF" to prevent the generator power from back-feeding
through the utility conductors. Typically, a user must then
manually configure one or more of the switches associated with the
load center to electrically connect the desired load circuits to
the generator power and electrically isolate the sources associated
with the utility and generator power signals.
[0004] In order to maintain electrical isolation between the
generator power input and the utility power input, the
connection/disconnection of the utility power supply and generator
power supply must be performed in a specific sequence to ensure
electrical isolation of the respective power input sources. Various
interlock and switching systems have been developed for carrying
out this function. One such system is shown and described in Flegel
U.S. Pat. No. 6,621,689 issued Sep. 16, 2003, and the disclosure of
which is hereby incorporated by reference in its entirety. While
the system shown in the '689 patent controls operation of a main
power supply ON/OFF switch and an auxiliary power supply ON/OFF
switch, it contains no provisions for controlling operation of
neutral switches associated with the main or utility power supply,
the auxiliary power supply, and the respective load circuits that
are configured to be discretely powered by one of the respective
power sources. Still other systems provide discrete switch
arrangements wherein operation of individual actuators is
associated with the conducting state of the discrete conductor
circuits associated with a single conductor.
[0005] Proper sequencing of the various conducting states of the
neutral and power or "hot" leads associated with the respective
loads and alternate power sources is a significant issue when
switching both the power (hot) and neutral conductors in power
transfer equipment. Failure to break the neutral conductor
connection last and make the neutral conductor connection first
during the power source switching event results in an open neutral
configuration that has the potential to allow high voltages (as
much as 240 VAC) to be applied to 120 VAC appliances. It should be
readily appreciated that providing voltages that are considerably
greater than the voltage for which a particular appliance is rated
has various undesirable effects, the least of which is the
potential damage to those appliances so subjected. Unfortunately,
many prior art devices fail to address such occurrences or require
complex switching sequences that could be inadvertently incorrectly
performed by users during power source switching activities without
proper switch interlock constructions. Unfortunately, providing
various switch interlock arrangements tends to complicate the power
source switching operation and can increase the cost associated
with forming a desired interlocking arrangement.
[0006] Therefore, there is a need for a single switch assembly that
switches both the hot and neutral wire associated with a given
circuit and does so in a manner that both first terminates or
breaks the neutral connection associated with the circuit and a
first power source and establishes a neutral connection of the
circuit with a supplemental or second power source prior to
connection of the power conductor with the supplemental power
source circuit.
[0007] For the above reasons, it is desirable to provide a switch
assembly that ensures electrical isolation of the utility power and
the generator power during a transfer of the input power from one
source to another, and which controls the sequence of operation of
neutral and power connection to circuits associated with the
utility and generator power supplies. The present invention
discloses a switch assembly and method of switching connection of a
load to alternate power sources that overcomes one or more of the
drawbacks mentioned above. Representatively, the switch assembly
includes a single actuator that, when engaged by the user,
effectuates the desired sequencing of making and breaking the power
and neutral connections between the load circuit and the alternate
power sources.
[0008] Therefore, a first aspect of the invention contemplates a
switch assembly that includes an actuator that is movable between a
first position and a second position. The switch assembly includes
a first movable element and a second movable element that are
operably coupled to one another and the actuator. A positive switch
contact arrangement is coupled with the first movable element and a
neutral switch contact arrangement is coupled with the second
movable element. The positive switch contact arrangement and the
neutral switch contact arrangement comprise geometrically different
constructions so that moving the actuator between a first position
and a second position avoids an open neutral condition.
[0009] Another aspect of the invention contemplates a switch
assembly having a first neutral contact, a second neutral contact,
a first power contact, and a second power contact. The assembly
includes a neutral conductor that is movable between a first
position in which the neutral conductor is electrically connected
to the first neutral contact and is electrically isolated from the
second neutral contact and a second position in which the neutral
conductor is electrically connected to the second neutral contact
and is electrically isolated from the first neutral contact. The
power conductor is movable between a first position in which the
power conductor is electrically connected to the first power
contact and is electrically isolated from the second power contact
and a second position in which the power conductor is electrically
connected to the second power contact and is electrically isolated
from the second power contact. A single actuator effectuates
sequential movement of the neutral conductor and the power
conductor between their respective first and second positions, such
that the neutral conductor remains in its first position after the
power conductor moves from its first position, and arrives at its
second position before the power conductor arrives at its second
position.
[0010] Another aspect of the invention that is useable or
combinable with one or more of the aspects above contemplates a
method of switching a load between a first power source and a
second power source. The method includes providing an actuator
having a first portion and a second portion. The first portion of
the actuator is shaped for cooperation with a neutral conductor
that is selectively electrically connectable to one of a first
neutral contact and a second neutral contact and is not
electrically isolatable from a third neutral contact. The second
portion of the actuator is shaped for cooperation with a power
conductor that is selectively electrically connectable to one of a
first power contact and a second power contact and is not
electrically isolatable from a third power contact. The actuator is
positionally associated relative to the neutral conductor and the
power conductor so that movement of the actuator from a first
position to a second position both 1) electrically isolates the
neutral conductor from each of the first neutral contact and the
second neutral contact before the power conductor is electrically
isolated from a respective one of the first power contact and the
second power contact and 2) electrically connects the neutral
conductor to one of the first neutral contact and the second
neutral contact before the power conductor is electrically
connected to the other respective one of the first power contact
and the second power contact. Such operation prevents open neutral
and over power conditions in the underlying circuits and does so in
a manner that requires only limited user interaction with the
switch assembly to effectuate the desired switching of the load
between the first and second power sources.
[0011] These and various other features, aspects, and advantages of
the invention will be made apparent from the following description
taken together with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The drawings illustrate the best mode presently contemplated
of carrying out the invention.
[0013] In the drawings:
[0014] FIG. 1 depicts an elevation view of a switch assembly
according to the present invention with the movable parts of the
switch assembly in a first configuration.
[0015] FIG. 2 depicts a perspective view of the switch assembly
shown in FIG. 1 from an opposite lateral side of the assembly but
still in the first configuration.
[0016] FIG. 3 depicts a view similar to FIG. 1 and shows a housing
of the switch assembly, with the switch assembly in the first
configuration wherein both the power and neutral conductors of a
load are electrically connected to the power and neutral conductors
associate with a first power source.
[0017] FIG. 4 depicts a view similar to FIG. 3 and shows the switch
assembly moved partially away from the orientation shown in FIG. 3
wherein the load power conductor is no longer electrically
connected to a power conductor associated with the first power
source but the neutral load conductor remains electrically
connected to the neutral conductor associated with the first power
source.
[0018] FIG. 5 depicts a view similar to FIG. 3 and shows the switch
assembly in an intermediary configuration wherein the neutral and
power conductors associated with a given load are electrically
isolated from both the first and second power sources.
[0019] FIG. 6 depicts a view similar to FIG. 3 and shows the
neutral conductor associated with a load electrically connected and
the power conductor electrically isolated, respectively, from the
second or alternate power source.
[0020] FIG. 7 depicts a view similar to FIG. 3 and shows the switch
assembly in a second configuration in which the neutral and power
conductors associated with a load electrically connected to the
power and neutral conductors associated with an alternate power
source, respectively, and electrically isolated from the first
power source.
DETAILED DESCRIPTION
[0021] FIGS. 1-7 show a rocker-type switch or switch assembly 10
according to a representative embodiment of the present invention.
Referring to FIGS. 1 and 2, switch assembly 10 includes a first
control member or first movable element 12 and a second control
member or second movable element 14 that are operably coupled to
one another via a movable actuator 16 of the switch assembly 10.
The switch assembly 10 may be in the form of a single-pole,
double-throw switch assembly or any other such type of switch
generally known in the art. As will be discussed in further detail,
the first and second movable elements 12 and 14 are constructed so
as to be geometrically different from one another but connected so
as to be movable together.
[0022] As explained further below, the geometrical differences
between movable elements 12, 14 result in the ability of one of the
movable elements to make an electrical connection with a respective
portion of a circuit associated with the respective movable element
before making of an electrical connection associated with the other
movable element, and conversely to break the electrical connection
associated with the same circuit before making of the electrical
connection associated with the respective portion of the circuit
associated with the other movable element. In this manner, the
particular construction of movable elements 12, 14 results in a
switch assembly 10 that operates in a predetermined electrical
connection sequence without requiring additional interaction by the
operator with the switch assembly or supplemental interlocking
structures. That is, the operator need only carry out a single
switching action, i.e., movement of an actuator associated with the
switch assembly between relative positions, to guarantee proper
sequencing of the making and breaking of the electrical connections
associated with a circuit.
[0023] Still referring to FIGS. 1 and 2, user manipulation of
actuator 16 controls movement of movable elements 12 and 14 via
translation of respective rockers or power and neutral conductors
18, 20 relative to the respective movable elements 12, 14. Elements
12, 14 can be configured in the form of outwardly biased plungers
that cooperate with or are received in corresponding cylindrical
receivers 22, 24 associated with actuator 16. Alternatively, it is
appreciated that elements 12, 14 can be integrally formed with
actuator 16. Elements 12, 14 are representatively disposed normal
to an upper surface 66, 67 of the respective movable power and
neutral conductors 18, 20 so that movable elements 12, 14 translate
relative to the respective power and neutral conductors 18, 20 and
effectuate rotation or rocking movement of each of conductors 18,
20 relative to at least two power contacts and at least two neutral
contacts associated with an underlying circuit to effectuate making
and breaking of an electrical connection between a circuit
associated with a load and the respective neutral and power
contacts associated with alternate power sources.
[0024] As shown schematically in FIGS. 1 and 2, in which it should
be noted that the views shown respectively therein are from
opposite lateral sides of the switch assembly 10 or from sides of
the switch assembly that are generally normal to a plane of
operation of actuator 16, switch assembly 10 is configured to
selectively cooperate with a power contact 26 and a neutral contact
28 associated with a first power source 30--such as a utility power
source. Switch assembly 10 is also configured to selectively
cooperate with a power contact 32 and neutral contact 34 associated
with a second power source 36--such as an auxiliary power source
such as a generator. For reasons set forth below, it is appreciated
that the orientations of power sources 30, 36 could be reversed
relative to switch assembly such that power source 30 could be
associated with a generator power and power source 36 could be
associated with a utility or other alternate power source. For
brevity, power sources 30, 36 are periodically referred to below
simply as alternate power sources.
[0025] An applicable load circuit or simply load 38 is
schematically indicated and can be electrically connected to the
alternate power sources 30, 36 via a power contact 40 and a neutral
contact 42 that are in electrical engagement with power conductor
18 and neutral conductor 20, respectively. It should be appreciated
that portions of the electrical connections between power source
30, power source 36, and load 38 shown in FIG. 1 are shown as
incomplete in as much as the neutral contacts 28, 34, 42 associated
with power sources 30, 36 and load 38, respectively, are hidden
from view as falling within the lateral footprint associated with
power contacts 26, 32, 40 when viewed from the perspective shown in
FIG. 1. It is however appreciated that various neutral and power
contacts could be provided in other relative positions such that
the respective power and neutral contacts associated with power
sources 30, 36 and load 38 do not otherwise directly overlie one
another when viewed from any particular vantage. It is further
appreciated that each of contacts 26, 28, 32, 34, 40, 42 can
include a stab 45 for electrically connecting each of the
respective contacts with the desired portion of a respective
circuit associated with power sources 30, 36 and load 38.
Representatively, stabs 45 are constructed to allow tool-less
engagement and removal of switch assembly 10 with the underlying
circuit structures. It is further appreciated that contacts 26, 28,
32, 34, 40, 42 can be referred to as stationary contacts as the
various contacts are commonly positionally fixed relative to one
another and the underlying circuits associated with power sources
30, 36 and load 38.
[0026] Regardless of the relative orientations of the various power
and neutral fixed position contacts, power conductor 18 includes a
first movable contact 46 and a second movable contact 48 that are
supported by a body 49 of power conductor 18. Neutral conductor 20
includes a first movable neutral contact 50 and a second movable
neutral contact 52 that are supported by a body 53 of neutral
conductor 20. Contacts 46, 48, 50, 52 are positionally fixed with
respect to a respective conductor 18, 20 but are described as being
movable due to the various relative positional associations of
contacts 46, 48, 50, 52 with respect to contacts 26, 28, 32, 34 as
a function of the relative orientation of the respective conductors
18, 20 relative to the corresponding respective contacts 46, 48,
50, 52 of switch assembly 10 associated with power sources 30, 36
and load 38.
[0027] Power contacts 46, 48 are disposed proximate generally
opposite ends 56, 58 of body 53 and offset from a center portion or
apex 60 formed along the longitudinal axis of body 53 of power
conductor 18. In a similar manner, neutral contacts 50, 52 are
disposed proximate generally opposite ends 61, 63 of body 49 and
offset from a center portion or apex 62 of neutral conductor 20.
Apex 60 of power conductor 18 is located proximate power contact 40
associated with load 38 whereas apex 62 of neutral conductor 20 is
located proximate neutral contact 42 associated with load 38.
[0028] Still referring to FIGS. 1 and 2, movable element 12
includes an exterior surface 64 that is shaped to slidably
cooperate with an upper surface 66 of power conductor 18. An apex
68 associated with surface 64 of movable element 12 slidably
cooperates with upper surface 66 of power conductor 18 to
effectuate rotation of power conductor 18 about apex 60 thereof. In
a similar manner, movable element 14 includes an exterior surface
70 that includes an apex 71 that is shaped to slidably cooperate
with an upper surface 72 of neutral conductor 20 to effectuate
rotation of neutral conductor 20 relative to apex 62 thereof.
[0029] Referring to FIGS. 1-3, actuator 16 defines a pivot axis 74
constructed to cooperate with a pivot pin 76 that extends along
pivot axis 74 and cooperates with a housing 78. Housing 78 includes
one or more tangs 80, 82 that each include a catch 84 for securing
housing 78, and the actuator 16 supported thereby, relative to the
remainder of switch assembly 10. When engaged therewith, movable
elements 12, 14 bias the contacts 46, 48, 50, 52, supported by
power and neutral conductors 18, 20, into respective alternate
engagements with contacts 26, 28, 32, 34, 40, 42 of switch assembly
10 in the manner described further below.
[0030] Bodies 49, 53 of power conductor 18 and neutral conductor 20
each have a generally bent shape that is defined by a first section
or portion 88, 90 and a second section or portion 92, 94 that
extend in generally opposite directions relative to the apex 60, 62
associated with the respective power and neutral conductor 18, 20.
Power and neutral conductors 18, 20 may have generally V or
U-shaped cross-sections or may form other shapes to allow isolated
interaction of the respective contacts of conductors 18, 20 with
the underlying contacts 26, 28, 32, 34. It is further appreciated
that conductors 18, 20 need not have the same or similar bent
shapes. For instance, conductor 18 may be shaped to define a
generally U-shape and conductor 20 may be shaped to define a
generally V-shape, or vice versa.
[0031] Regardless of their specific shape, conductors 18, 20 have
geometrically different shapes, in that the shape of neutral
conductor 20 is defined by a shallower bend angle than a bend angle
associated with power conductor 18. Surface 64 of first movable
element 12 defines a generally V or U-shaped actuation surface that
generally matches the bend angle of power conductor 18 and surface
70 of second movable element 14 defines a shallower V or U-shaped
actuation surface that generally matches the bend angle of neutral
conductor 20. As used herein, it is appreciated that surfaces 64,
70 need not exactly match the shape of conductors 18, 20,
respectively, but can be shaped to generally match of the shape of
the respective power and neutral conductor 18, 20 to effectuate the
desired motion of the respective conductors 18, 20 in response to
movement of the respective movable elements 12, 14 relative
thereto.
[0032] FIGS. 1-3 show switch assembly 10 in a first position,
configuration, or orientation in which an end or handle 96 of
actuator 16 is in a first position and movable elements 12, 14 are
in a first position relative to power and neutral conductors 18,
20. Referring to FIGS. 2 and 3, from this orientation, it should be
appreciated that power conductor 18 is electrically connected to
power contact 26 associated with power source 30 as well as load
power contact 42 whereas contact 48 of power conductor 18 is
electrically isolated from the power contact 32 associated with the
alternate power source 36. In a similar manner, as shown best in
FIG. 2, when actuator 16 is in the first position, neutral
conductor 20 is electrically connected to neutral contact 28
associated with power source 30 and load neutral contact 42, and
contact 52 of neutral conductor 20 is electrically isolated from
neutral contact 34 associated with the alternate power source 36.
Said another way, when actuator 16 is in a first position, switch
assembly 10 electrically connects a neutral portion and a power or
hot portion of a circuit associated with a load 38 to a neutral
portion and power or hot portion of a circuit associated with first
power source 30, and also maintains an electrical isolation of
power and neutral conductors 18, 20 from the neutral portion and
power portion associated with alternate power source 36 and from
the other conducting structures associated with switch assembly
10.
[0033] FIGS. 4-7 show various orientations of switch assembly 10 as
handle 96 associated with actuator 16 moves from the first
orientation or position (shown in FIG. 1-3) toward a second
orientation or position (shown in FIG. 7). Referring to FIG. 4,
partial rotation of actuator 16 via user interaction with handle 96
effectuates rotation of actuator 16 about pivot pin 76. Translation
of handle 96 in switching direction 98 effectuates translation of
movable elements 12, 14 in an alternate direction, indicated by
arrow 100, relative to power conductor 18 and neutral conductor
20.
[0034] As shown in FIG. 4, partial translation of handle 96
translates apex 68 of movable element 12 along surface 66 of power
conductor 18 and effectuates separation of fixed position power
contact 26 and movable power contact 46 associated with power
conductor 18. Still referring to the configuration shown in FIG. 4,
neutral contact 50 remains briefly electrically engaged with fixed
position neutral contact 28 associated with power source 30 after
separation of power contacts 26, 46. As the operator rotates handle
96 away from the first position, movable elements 12, 14 move
together so that a leading edge associated with movable elements
12, 14 contacts a portion of the respective power and neutral
conductors 18, 20 that is toward an open switch side of the
respective conductors 18, 20 and forces the power conductor 18 and
the neutral conductor 20 to sequentially separate the electrical
connections associated with contacts 26, 28 such that power
conductor 18 is electrically isolated from contact 26 prior to
neutral conductor 20 being electrically isolated from contact 28
associated with power source 30. That is, because neutral conductor
20 has a greater bend angle than power conductor 18, neutral
contact 50 remains engaged with the neutral contact 28 for a longer
period of time to enable breaking of the hot switch contacts 26, 46
prior to breaking the respective circuit neutral connection.
[0035] Referring to FIG. 5, continued translation of handle 96 in
direction 98, relative to the orientation shown in FIG. 4, results
in general alignment of apex 68 and apex 71 of movable elements 12
and 14 with the respective apex 60, 62 of the respective power
conductor 18 and neutral conductor 20. In the intermediary switch
position shown in FIG. 5, apexes 68, 71 of movable elements 12, 14
are generally aligned with apexes 60, 62 associated with the
respective power and neutral conductors 18, 20 and generally align
over the power and neutral contacts 40, 42 associated with load
circuit 38. In the orientation shown in FIG. 5, switch assembly 10
is shown at a midway point of its travel between the first position
of FIG. 3 and the second position shown in FIG. 7. At this midway
point, movable element 14 associated with the neutral conductor 20
contacts the obtuse or second portion 90 of neutral conductor 20
such that movable element 14 biases neutral conductor in a
direction that breaks the electrical connection between neutral
contacts 28, 50 associated with power source 30. Such a
configuration ensures that the neutral connection associated with
neutral contacts 28, 50 is not broken until after the power or hot
connection associated with power contacts 26, 46 is broken when
moving actuator 16 from the first position toward the second
position.
[0036] It should also be appreciated from the orientation shown in
FIG. 5, that the neutral and power contacts 26, 28 associated with
power source 30 and the neutral and power contacts 32, 34
associated with power source 36 are all electrically isolated from
the power contacts 46, 48 associated with power conductor 18 and
the neutral contacts 50, 52 associated with neutral conductor 20,
respectively, when switch assembly 10 is at the intermediary switch
location. Such a configuration electrically isolates load circuit
38 and power and neutral conductors 18, 20 of switch assembly 10
from both power sources 30, 36 simply via manipulation of actuator
16.
[0037] Referring to FIG. 6, continued translation of handle 96 in
direction 98, relative to the orientation shown in FIG. 5,
effectuates continued translation of first and second movable
elements 12, 14 in direction 100 relative to power conductor 18 and
neutral conductor 20. At the intermediary switch position shown in
FIG. 6, it can be appreciated that neutral contact 52 associated
with neutral conductor 20 is electrically connected to neutral
contact 34 associated with alternate power source 36 while power
contact 48 associated with power conductor 18 remains electrically
isolated from power contact 32 associated with power source 36.
Opposite to the positional orientation shown in FIG. 4, power
contact 46 and neutral contact 50 associated with power conductor
18 and neutral conductor 20, respectively, remain electrically
isolated from the neutral and power contact 26, 28 associated with
power source 30 when switch assembly 10 is in the configuration
shown in FIG. 6.
[0038] Still referring to FIG. 6, switch assembly 10 is shown
moving past the midway point shown in FIG. 5 and toward the second
position of actuator 16 as shown of FIG. 7. In the position shown
in FIG. 6, the movable elements 12 and 14 are being forced toward a
closed position by action of springs or similar such biasing
associated with the interaction of movable elements 12, 14 with
power and neutral conductors 18, 20. Such a bias can be provided by
the geometric cooperation of movable elements 12, 14 with power and
neutral conductors 18, 20 and the positional association of fixed
position contacts 26, 28, 32, 34, 40, 42 and or via a compression
spring provided between actuator 16 and movable elements 12, 14. In
the latter configuration, it is appreciated that such a spring can
be provided in the opening 22, 24 associated with the interaction
of each or movable elements 12, 14 with actuator 16. It is
appreciated that such a construction would provide a slidable
interaction between movable elements 12, 14 and actuator 16, in a
manner as is known.
[0039] As movable elements 12, 14 translate relative to conductors
18, 20 or rotate relative to pivot pin 76, cooperation of a
trailing edge of movable element 12 with portion 92 of power
conductor 18 prevents closure of power contacts 32, 40 associated
with power conductor 18 and power source 36 until actuator 16
achieves the second position associated with FIG. 7. On the other
hand, the more obtuse angle associated with movable element 12 and
neutral conductor 20 allows neutral conductor 20 to move in a
generally unobstructed manner to effectuate the electrical
interaction of neutral contact 52 of neutral conductor 20 and
neutral contact 34 associated with power source 36, such that an
electrical connection between neutral contacts 34, 52 is
established before an electrical connection between power contact
48 of power conductor 18 and contact 32 associated with power
source 36. In this manner, switch assembly 10 prevents the
occurrence of an open-neutral condition as discussed above.
[0040] FIG. 7 shows actuator 16 in a second position in which
movable elements 12, 14 have been fully translated in direction 100
relative to power conductor 18 and neutral conductor 20 so as to
bias movable power contact 48 into engagement with stationary power
contact 32 associated with power source 36, after neutral contact
52 associated with neutral conductor 20 has been electrically
connected to stationary neutral contact 34 associated with power
source 36. This second position of actuator 16 also maintains the
electrical separation between movable power contact 46 and movable
neutral contact 50 associated with power conductor 18 and neutral
conductor 20, respectively, with the respect to stationary power
and neutral contacts 26, 28 associated with power source 30.
[0041] In the configuration shown in FIG. 7, power conductor 18 and
neutral conductor 20 electrically connect power contact 32 and
neutral contact 34 associated with power source 36 with the
respective power contact 40 and neutral contact 42 associated with
load 38 via power and neutral conductors 18, 20, respectively. From
the position shown in FIG. 7, actuator 16 is movable in an opposite
direction, indicated by arrow 104, relative to direction 98 (FIGS.
3-6) to effectuate an opposite sequencing of the switching of the
conducting state of movable power conductor 18 and movable neutral
conductor 20 for returning load contacts 40, 42 to an electrically
conductive configuration with contacts 26, 28 of power source 30
when so desired.
[0042] Similar to the description provided above with respect to
FIG. 3, when in the second position as shown in FIG. 7, portion 94
of neutral conductor 20 is positioned at an angle relative to
horizontal that is less than the angle of portion 92 of power
conductor 18. Arranging the respective portions 88, 90, 92, 94 of
the neutral and power conductors 18, 20 in such a manner allows
switch assembly 10 to return load 38 to a conducting arrangement
with power source 30 when so desired via manipulation of actuator
16 in opposite direction 104 and allows a similar sequencing of the
making and breaking of the neutral and power connections with the
respective power sources 30, 36 and the respective circuit
associated with a particular load 38. That is, switch assembly 10
is configured such that, for example, when switching from primary
or utility power to a secondary, auxiliary, or generator power, the
main power is first switched "OFF", then the main neutral is
switched "OFF", then the generator neutral is switched "ON" and
finally the generator power is switched "ON". Understandably, when
switching from the generator or secondary power to the main or
primary power, this sequence is reversed. In this way, switch
assembly 10 is configured to avoid open neutral conditions by
virtue of the configurations of movable elements 12, 14 and their
respective cooperation with power and neutral conductors 18, 20 and
requires but a single action on the part of the operator to ensure
a proper disconnect and connect sequencing regardless of the
switching direction between first and second power sources such as
utility and auxiliary power sources.
[0043] When actuator 16 is positioned in one of the first and
second positions, the angles of the disengaged portions, i.e.,
portions 88, 90 in FIG. 3 and portions 92, 94 in FIG. 7, are
arranged at disparate angles relative to horizontal defined by an
upper surface of the respective stationary power and neutral
contacts 26, 28, 32, 34, 40, 42. In particular, when in the first
position shown in FIG. 3, portions 90, 94 of neutral conductor 20
are arranged at angles relative to horizontal that is less than an
angle of the portions 88, 90 of power conductor 18 relative to
horizontal. Said in another way, the angle between portions 90, 94
associated with neutral conductor 20 is greater than or more obtuse
than the corresponding angle between portions 88, 92 of power
conductor 18. For example, the angle between the portions 88, 92 of
power conductor 18 may be on the order of approximately 125 degrees
while the angle between the portions 90, 94 associated with neutral
conductor 20 may be on the order of approximately 150 degrees. Of
course, other angular relationships may be utilized in keeping with
the present invention.
[0044] As described above, switch assembly 10 includes an actuator
16 that is selectively engageable by an operator for moving the
actuator 16 between a first position (FIG. 3) and a second position
(FIG. 7). In the first position, the switch assembly 10 operably
electrically connects a circuit associated with a load 38 to a main
or utility power source 30, while in the second position the switch
assembly 10 operably electrically couples the load 38 with an
auxiliary power source 36. It is appreciated that actuator 16 may
be in the form of a standard paddle-type actuator of the kind
generally known in the art. The actuator 16 is pivotable relative
to a housing, such as housing 78, for moving the first and second
movable elements 12 and 14 relative to the pivotable or movable
conductors 18, 20 as described above to effectuate the desired
isolated electrical switching of the circuit associated with load
38 for electrical connection with a respective desired power source
30, 36.
[0045] As such, switch assembly 10 provides a switch configuration
in which the neutral and power connections associated with a
particular load can be electrically connected to alternate power
sources in a manner that avoids an open neutral condition, that
allows making and breaking the neutral connections before and
after, respectively, the making and breaking of the power or hot
electrical connections associated with either of the respective
power sources, and does so in a manner that only requires user
interaction with a single actuator or user movable member of the
switch assembly.
[0046] Various embodiments are described in detail with reference
to the drawings, wherein like reference numerals represent like
parts and assemblies throughout the several views. Reference to
various embodiments does not limit the scope of the claims attached
hereto. Additionally, any examples set forth in this specification
are not intended to be limiting and merely set forth some of the
many possible embodiments for the appended claims.
* * * * *